Control Global

Hunter Vegas from Wunderlich Malec and Ned Espy and Roy Tomalino from Beamex present a two-part ISA webinar on the basics, crucial issues and best practices for successful pressure calibration.

As natural forces go, pressure is pretty straightforward. It involves less mysterious physics than electromagnetism, it's easier to observe than thermodynamics, and its calculations are simpler than often turbulent flows. However, there are still…

This State of Technology Report is a compendium of the latest trends articles, back-to-basics tutorials, application stories and product solutions recently published in the pages of Control—compiled by the editors and all together here in one convenient eBook.

Despite ongoing advances in instrumentation technology, specifying a flowmeter or level gauge that will reliably perform over the anticipated range of process conditions often remains a complex and subtle engineering task.
Dozens of niche…

Process plants and related facilities such as tank farms are filled with vessels, tanks and similar storage units, and most of these units could benefit from a system to measure, monitor and view inventory on a near real-time basis. "Logistical…

Additional information and wireless connectivity are further improving productivity, reliability and efficiency.

Like other facilities that have been using the HART Communication Protocol for any amount of time, previous recipients of the HART Plant of the Year Award have been busy reaping even more of the benefits the technology provides. These benefits…

BLH Nobel Introduced a System That Quickly and Easily Checks Weighing Systems for Wiring and Mechanical Faults

Load cell weighing systems solve some of the knottiest problems in batch and level control by directly measuring masses of solids and liquids as they're accumulated, dispensed or conveyed. But the load cells must be installed and wired properly, and the load structure must be engineered and constructed correctly to distribute the measured load as axial forces on the cells. What appear on the surface to be simple wiring and construction tasks have caused more than a few problems during commissioning and maintenance due to miswired or poorly made connections, distorted or binding structures, incorrectly installed load cells or rigid connections to adjacent equipment.
Such problems often are not found until a new installation is being…

Recent

Greg McMillan and Stan Weiner Speak with Electrochemical Measurements Expert Jim Gray About the pH Electrode and Its Full Potential as a Measuring Tool

Stan: A measurement is only as good as its calibration. The pH electrode has by far the greatest sensitivity and rangeability of any measurement in the process industry. The electrode can function well in a wide spectrum of process fluids and…

This month, the editors of Control browse the web to get you the latest online resources on loop control. Here's how you can stay in the loop!

This System Is Closed
This is a basic tutorial on closed-loop control systems. It covers the basic definitions and descriptions of how closed-loop systems work, a discussion of closed-loop summing points and how to use them, transfer functions, multi-loop closed-loop systems and closed-loop motor control. The direct link is www.electronics-tutorials.ws/systems/closed-loop-system.html.Electronics Tutorials www.electronics-tutorials.ws
PID Control
VeriCal in-situ calibration verification This is a basic discussion, with illustrations, of the principles of Proportional, Integral, Derivative (PID) and how it is used with controllers. It also covers tuning rules and starting settingf for common control loops. The direct link is at…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

A Frost & Sullivan report, "Programmable Logic Controllers Market," finds that the market earned revenues of $10.37 billion in 2013 and estimates this will reach $14.58 billion in 2018.

According to analyst firm Frost & Sullivan, the global PLC market, which witnessed a strong decline in growth in 2012 due to the uncertain economic scenario in the developed world, has bounced back. Since 2013, it has witnessed positive growth, particularly in the Asia-Pacific region, where the rebound has been fueled by increased activity, especially in the construction, water and wastewater and power industries.
A Frost & Sullivan report, "Programmable Logic Controllers Market," finds that the market earned revenues of $10.37 billion in 2013 and estimates this will reach $14.58 billion in 2018.
In Europe, the need to enhance efficiency and comply with regulations, as well as improve safety and control capabilities, are driving…

ABB is participating in the ISA106 committee's efforts to go beyond layers of protection, and integrate sequential and procedural safety methods into process control applications

Process safety is about a lot more than armoring up against threats and mishaps, and it's time that many process operators, engineers and managers knew it.
Process manufacturers have long used hazards and operability (HAZOP) studies, layers of…

Control Engineering Branches Out to Manage Critical Business Variables Such as Profitability, Risk, Asset Management and Cybersecurity

Most process engineers I talk to look back on the 1970s and 1980s as the heyday of control engineering, and in many ways it was. More engineers were focused on the applications of real-time control theory then than now. And when you look at how far…

The Latest in Computing Technology Is Here

VERSATILE AUTOMATION COMPUTERS These four new computers are designed for the challenging requirements of the machine automation industries. UNO-3073 and UNO-3073GL have Intel Celeron 1.1- MHz and 1.0-MHz processors; UNO-3083G and UNO-3085G have Intel Core i7 2.2- MHz processors. They have up to five PCI/PCIe expansion slots and support high-speed PCIe x16, x8, x4 and x1 cards and legacy PCI cards. Advantech Industrial Automation Group 800-205-7940www.advantech.com/ea
GAME-CHANGING PACs PACSystems RXi, a new control and computing platform, is designed for the needs of the industrial Internet. The core of the product family is a COM Express architecture with multi-core CPUs. Its configurations are unique in the industry, and able to…

New robot innovations are changing the way manufacturers load and unload machines

Say good-bye to expensive manual machine loading and unloading in harsh environments. Say hello to robotics.
If you haven’t been introduced already, robots are designed to help with reducing production costs, increasing flexibility and improving…

Since the goal is to control loop stability, the choice that gives you the best chance of that is the one to make.

Question:
Is there some general rule on when we should use =% (equal percentage) and when linear control valves? I know that the determining factor is the inherent flow characteristic, the flow vs. lift at constant pressure drop, or something like…

After six decades of developing on/off valve automation solutions, it might seem logical for Emerson Process Management to pause and take a well-deserved breather. But anyone who thinks that doesn't know how this company works. Just like the…

Smart Drives, Mechatronics, Variable-Speed Drives and More Power Options

MEDIUM-VOLTAGE AC DRIVE MV1000 medium-voltage ac drives combine compact modular design, high efficiency and a good MTBF rate. Smart Harmonics technology reduces input total harmonic distortion to less than 2.5% without filters, which exceeds the requirements of IEEE519-1992. It also provides galvanic isolation between power input and output, and uses two 5-V step bridges per phase to generate a 17-level, line-to-line voltage output delivered to the motor. Yaskawa800-927-5292
VSD WITH SMARTSAltivar Process is a range of VSDs from 1 hp to 1,500 hp that come with embedded process knowledge, configurable on-board dashboards and a graphical HMI display. An advanced, secure, integrated web server lets operators access technical…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

101 solutions and strategies for navigating the complex field of membrane switch design.

Pannam Imaging published 101 solutions and strategies for navigating the complex field of membrane switch design to help their readers and customers understand the many facets of membrane switch technology. The extensive lists of tips includes membrane switch applications, user interface design and human-machine interaction, the use of PCBs (printed circuit boards), backlighting options and other technologies, tactile feedback and other design considerations, and membrane switch and electronics industry trends.
With Pannam Imaging's permission, we brigng you the first ten. At the end of the article you willl have a link to access all 101 tips.
Membrane switches are used in many applications that you use every day. “Keypads have…

When instruments "talk" back, their messages become priority. Don't want to miss the alert saving you from an a plant shutdown.

As we're hurried forward into the promised new "Industrial Internet of Things" - the "IIoT," a.k.a. "pervasive sensing," will we find the presumed wealth of previously hidden information useful or interesting? Surely there will be something I care…

The GX and GP Products Are the First of a New SmartDAC+ Product Family

Yokogawa has released the GX and GP Series of digital data acquisition systems, products that go far beyond functionality of the original paperless recorder. Complementing Yokogawa's DXA Advanced R4 series, the GX and GP bring some features that are…

Recent

Because Big Data is Really More of the Same Data, Engineers and Other End Users Find Ways to Take Advantage of New Sources of Intelligence

I'm sorry to be a downer at the start of a shiny New Year, but I'm continually reminded that most new and unfamiliar technical concepts are just more of the same old concepts. Big data is really more of the same data. The Internet of Things (IoT)…

Download this free technology report and get the latest information from connectors and cordsets to intrinsic safety and power supplies.

In this exclusive, 35-page eBook from the editors of Control you will find an exclusive collection of our best technology trends, back-to-basics tutorials and application stories on all things I/O.
The technology report is divided in three section:…

Diagnosing a signaled instrument failure is tricky, time-consuming and usually is called for at a most inconvenient time, but better diagnostics are making the task easier.

Physical Layer Diagnostic Improvements
Why is it, after weeks of seemingly trouble-free plant operation, the phone rings on the holiday weekend when the goose is in the oven and the table is set for dinner? Fortunately for me, the crew on shift was…

A badly designed network is often the weakest link in the system.

IoT's Weakest Link
A common conversation among many industrial networking specialists these days revolves around whether we should be distinguishing between wired and wireless networks. WINA, of which I am chairman, is one organization taking a…

A report published by Smart Industry says that the future of manufacturing plants will be based on the efficiency capabilities smart tools are bringing to the table.

A report published by Smart Industry says that the future of manufacturing plants will be based on the efficiency capabilities smart tools are bringing to the table.
Bringing the Industrial Internet to hand-held devices on the factory floor, enhances productivity, production quality, and work safety.
Theresa Woodiel, National Instruments' Global Campaign Manager, Embedded Systems, recently spoke with Smart Industry and talked about how the company is helping Airbus optimize their factory floor. They are upgrading Airbus's sensors, software and data technology, putting the power and control on individual workers' hands. Smart tools are a key element in the process, communicating with both the factory-wide infrastructure, with the individual…

Download this free technology report and get the latest information from connectors and cordsets to intrinsic safety and power supplies.

In this exclusive, 35-page eBook from the editors of Control you will find an exclusive collection of our best technology trends, back-to-basics tutorials and application stories on all things I/O.
The technology report is divided in three section:…

Mobility's True Value Lies in Enabling New Possibilities

Rockwell Automation takes seriously the needs of its users to access information when on the go. For years now, they've offered the ability to send text or email notifications to mobile devices or replicate in-plant or desktop user interfaces on…

Recent

Download this free technology report and get the latest information from connectors and cordsets to intrinsic safety and power supplies.

In this exclusive, 35-page eBook from the editors of Control you will find an exclusive collection of our best technology trends, back-to-basics tutorials and application stories on all things I/O.
The technology report is divided in three section:…

$5-billion transaction will more than double Olin’s scale

The boards of directors of Dow Chemical of Midland, Michigan, and Olin Corporation of Clayton, Missouri, have unanimously agreed to a deal by which Dow will separate a significant portion of its chlor-alkali and downstream derivatives businesses and…

Version 6 of System 800xA process control system offers a host of new capabilities, integrates with more application areas, and provides more useful functions for users.

Some Swiss Army knives just get better—to the point where it seems they can go anywhere and accomplish almost anything.
System 800xA (eXtended Automation) is one of these universally helpful tools; and its new version 6 (v6) is continuing this tradition by helping users with many new and improved features via new avenues to help people, equipment and systems cooperate more effectively. This new version is available now for new projects. Pricing will be available in April, and it will launch for upgrade projects in June.
"Anything you can bring in with System 800xA is available to all systems," explained Roy Tanner, ABB's global product marketing manager for 800xA. "Users can call up devices and data from multiple suppliers and show…

Coca-Cola and GE Lighting Use Proficy Workflow, Historian, iFix HMI SCADA and Portal Software to Streamline Lighting and Refreshment Production

Seeing is believing, and bringing operational information into the light makes it usable by everyone in an enterprise—allowing them all to make faster, more productive decisions.
This enhanced awareness was especially useful at GE Lighting,…

$5-billion transaction will more than double Olin’s scale

The boards of directors of Dow Chemical of Midland, Michigan, and Olin Corporation of Clayton, Missouri, have unanimously agreed to a deal by which Dow will separate a significant portion of its chlor-alkali and downstream derivatives businesses and…

Find out what certification ABB Canada received and what B&B ELectronics' new name is.

ABB's operations in Canada have been certified by TÜV SÜD as having in place and applying a functional safety management system (FSMS) for the design and engineering of safety instrumented system (SIS) projects in accordance with industry good practice safety standards. These standards include IEC 61508 and IEC 61511 for the integration and implementation of safety instrumented systems. Networking technology provider B&B Electronics has changed its name to B+B SmartWorx. While continuing to develop mission-critical network connectivity technology for remote or demanding environments, B+B SmartWorx is expanding into the emerging Internet of Things market and embedding intelligence throughout the network connectivity stack from edge…

The number of global Internet users will double to 4 billion by 2020, with ever more of these users—about three quarters of them—living in emerging economies. Along with these rising numbers will come an exponential increase in cybersecurity…

What do 9/11, the Detroit Bomber and ICS Security Have in Common?

By Walt Boyes, Editor in Chief
In his "Unfettered" blog post, "What do 9/11, the Detroit Bomber and ICS Security Have in Common," Joe Weiss makes a really good point: The result of all governments' responses to the Dec. 25 incident on the approach…

Recent

Will Electronic Marshalling Mean the End of the "Bespoke" Enclosure?

Unlike clothing fashions, enclosure styles don't change a lot from year to year. A 40-year-old enclosure doesn't stand out like your dad's leisure suit. After all, a big metal box is pretty much a big metal box, even with the added glitz of…

In today’s flat world, process industry firms have access to the same equipment and the same automation hardware and software, similar external engineering and system integration resources, and capital at comparable costs.

Given all these similarities, what separates the winners from the losers? Management—more specifically process engineering and automation management. But because management is a two-way street, and because even the best managers can be thwarted by incompetent or uncooperative subordinates, there’s a second key determinant of success.

That would be those subordinates and their relationships with their managers. It’s easy to blame management for all problems, but, in reality, all employees have a part to play.

What determines good management and good manager/subordinate relationships? Textbook definitions are useful, but often trite. The real answers come from people just like you, the managers and subordinates working in process industry firms.

What Makes a Good Manager?

The essential traits for a good process automation manager come by the dozens, but number one on most lists is technical acumen. “Managers must truly understand what automation employees do from a technical standpoint,” observes Dale Evely PE, principal engineer I&C at Southern Co. in Birmingham, Ala. “Not understanding causes employee dissatisfaction because commitments are made to customers that can’t be met properly.”

Managers must be strong technically to see the big picture. “Managers must understand the entire system and how it affects different parts of the plant as well as the business,” comments Gary Crenshaw, corporate engineer at Beam Global Spirits and Wine in Clermont, Ky. “They must keep up to date with current technology and have plans for obsolescence,” he continues.

Richard McCormick, automation engineer with Mick Automation in Levis, Quebec, an industry consultant with extensive plant operations experience, sees things the same way. “A strong technical background is mandatory, and this background should cover the site’s automation system specifics as much as possible. One simply can’t manage highly technical resources efficiently without knowing and understanding what they’re doing on a daily basis,” emphasizes McCormick.

Managers must observe and monitor the progress of their employees, but they need to let them accomplish tasks independently.Courtesy of Rockwell Automation.

Shared technical competency among managers and subordinates creates an environment where mutual respect can flourish. “If the employees that work under you believe that you’re technically capable, they then value your opinion and believe that you’re making valid suggestions,” notes Darren Pillay, MES consultant with Sasol Technology in Johannesburg, South Africa.

“As a manager, you must understand the technical capabilities of other employees. Understanding their technical weaknesses and strengths enables an automation manger to select the best person for the intended work package,” observes Pillay.

Chaos reigns when managers don’t understand the technology. “Managers must understand, document, and enforce the operational philosophy of the plant,” emphasizes Jeff Waufle, IT technical services supervisor for the Las Vegas Valley Water District. “Well-meaning staff will constantly try to bend the philosophy by introducing improvements. Strong technical management of change policy will help keep automated processes true to the original intent.”

Talk To Me

In addition to technical acumen, process automation managers need great communication skills, and employ them at multiple levels. First, managers must communicate effectively and often with their subordinates. Second, they must be able to convince their superiors in senior management that automation can deliver tangible business benefits. Third, they must negotiate with other peer-level managers on items such as resource needs.

“Managers must be able to articulate process control needs and value to customers, and they must motivate engineers to focus on end results instead of what seems cool,” observes Dan Cox, director of manufacturing systems at AOC Resins in Collierville, Tenn., summing up the importance of communication skills up and down the managerial chain.

“Managers must be able to relate an automation process in laymen’s terms to the customer and/or the end user,” says Pete Atkinson, an MIS engineer with Boehringer Ingelheim Vetmedica in St. Joseph, Mo. Speaking to less technically astute folks is something automation managers need to do every day, and this requires important communication skills such as empathy, patience and understanding.

The traditional boss/subordinate role is between an engineering manager and a technical professional, but perhaps a more important indirect supervisory relationship exists between technical professionals and plant operators. The best process automation system in the world can be rendered ineffective pretty quickly if plant operators aren’t on board.

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